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Abstract:

A thermoplastic injection molding system and method of use is described
for molding parts from heated plastics and other organic resins. The
machine uses heat sources located along the barrel to heat the source
material while an auger screw transports the source material in the
barrel. This transport step does not shear the source material, nor does
it use friction to produce the heat necessary to melt the source
material. The material becomes substantially liquid or melted during the
heating process, and the melted material is forced, by the auger screw,
into a chamber whereupon a plunger, situated concentrically with the
auger screw, injects the material from the chamber into a mold. Sensors
located along the barrel and in the chamber ensure consistency between
mold cycles. The controller dynamically adjusts the injection molding
process to achieve more consistent and reliable molded parts.

Claims:

1. A machine for injection molding comprising: a barrel having an
interior and having a longitudinal axis; a screw auger positioned within
the barrel interior, wherein the screw auger is substantially concentric
with the barrel and is operable to rotate and transmit a material along
the length of the barrel, wherein the screw auger includes a bore also
substantially aligned with the longitudinal axis; a heating element in
thermal communication with said barrel; an injection chamber; a channel,
wherein the channel provides fluid communication between the injection
chamber and the barrel; a plunger substantially aligned for movement
along the longitudinal axis and with the bore and being substantially
coaxial with said screw auger, wherein the plunger in a first position
impedes fluid communication between the barrel and the injection chamber,
wherein the plunger in a second position does not impede fluid
communication between the barrel and the injection chamber; an injection
tube wherein the injection tube is in fluid communication with the
injection chamber, and wherein the injection tube is located adjacent the
plunger; and a temperature sensor in communication with one of the
barrel, the injection chamber, and the injection tube; wherein rotation
of the screw auger is dependent of a first pressure reading obtained from
a first pressure sensor and a second reading of a second pressure sensor,
wherein the first reading is indicative of a force applied to the screw
auger in a direction that is substantially along the longitudinal axis,
and wherein the second reading is indicative of a pressure of the
material when heated to at least a flowable state; wherein a barrier is
formed by the compaction of pellets within said barrel as said pellets
travel toward a melting zone, said barrier preventing melting plastic
from flowing backward in said machine, said machine being devoid of a
valve that prevents substantial flowback of melted plastic.

2. The machine as set forth in claim 1, wherein said plunger rotates with
the rotation of the screw auger.

3. The machine as set forth in claim 1, wherein a coolant reservoir is
provided to prevent excessive heat from the plastication of pellets from
being transferred to a throat block.

4. A method of injection molding comprising: transmitting, by a screw
auger, a material along a barrel, the barrel having an interior with a
longitudinal axis, the screw auger positioned within the barrel interior,
the screw auger being substantially concentric with the barrel, the screw
auger being operable to rotate, and the screw auger including a bore also
substantially aligned with the longitudinal axis; heating the material
within the barrel by a heating element in thermal communication with the
barrel and capable of heating the material to a flowable state;
transmitting, to a channel and by the screw auger, the material, the
material being in a flowable state; receiving, by an injection chamber
and from the channel, the material, wherein the channel provides fluid
communication between the injection chamber and the barrel; urging, by a
plunger, the material in the injection chamber into an injection tube,
wherein the plunger is substantially aligned for movement along the
longitudinal axis and with the bore, wherein the plunger is substantially
coaxial with the screw auger, and wherein the plunger is capable of
translating along an axis of the plunger relative to the screw auger,
wherein the plunger in a first position impedes fluid communication
between the barrel and the injection chamber, wherein the plunger in a
second position does not impede fluid communication between the barrel
and the injection chamber; receiving by an injection tube, the material
urged by the plunger, wherein the injection tube is in fluid
communication with the injection chamber, and wherein the injection tube
is located opposite the plunger; relating the rotation of the screw auger
upon a first pressure reading obtained from a first pressure sensor and a
second reading of a second pressure sensor, wherein the first reading is
indicative of a force applied to the screw auger in a direction that is
substantially along the longitudinal axis, and wherein the second reading
is indicative of a pressure of the material when heated to at least a
flowable state, said screw auger configured within said barrel in a
manner that substantially prevents the plastic being conveyed therein
from being sheared, with tolerances between said screw and said barrel
being sufficient such that gaps between an inside diameter of said barrel
and an outside diameter of said screw are small enough so that plastic
pellets cannot be sheared therebetween; and forming a barrier by
compacting pellets within said barrel to prevent melting plastic from
flowing backward as said pellets travel toward a melting zone, the
injection molding method performed without employing a valve that
substantially prevents a flowback of melted plastic.

5. The method as set forth in claim 4, further comprising providing a
coolant reservoir to prevent excessive heat from the plastication of
pellets from being transferred to a throat block.

6. A machine for injection molding comprising: a barrel having an
interior and having a longitudinal axis; a screw auger positioned within
the barrel interior, wherein the screw auger is substantially concentric
with the barrel and is operable to rotate and transmit a material along
the length of the barrel, wherein the screw auger includes a bore also
substantially aligned with the longitudinal axis; a heating element in
thermal communication with said barrel; an injection chamber; a channel,
wherein the channel provides fluid communication between the injection
chamber and the barrel; a plunger substantially aligned for movement
along the longitudinal axis and with the bore and being substantially
coaxial with said screw auger, wherein the plunger in a first position
impedes fluid communication between the barrel and the injection chamber,
wherein the plunger in a second position does not impede fluid
communication between the barrel and the injection chamber; an injection
tube wherein the injection tube is in fluid communication with the
injection chamber, and wherein the injection tube is located adjacent the
plunger; and a temperature sensor in communication with one of the
barrel, the injection chamber, and the injection tube; wherein rotation
of the screw auger is dependent of a first pressure reading obtained from
a first pressure sensor and a second reading of a second pressure sensor,
wherein the first reading is indicative of a force applied to the screw
auger in a direction that is substantially along the longitudinal axis,
and wherein the second reading is indicative of a pressure of the
material when heated to at least a flowable state; wherein a barrier is
formed by the compaction of pellets within said barrel as said pellets
travel toward a melting zone, said barrier preventing melting plastic
from flowing backward in said machine, said machine being devoid of a
valve that prevents substantial flowback of melted plastic; wherein a
coolant reservoir associated with said barrel to prevent excessive heat
from the plastication of pellets from being transferred to a throat
block.

7. The machine as set forth in claim 6, wherein said plunger rotates with
the rotation of the screw auger.

Description:

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a continuation application of
application Ser. No. 12/429,177, filed Apr. 23, 2009 and claims the
benefit of U.S. Provisional Patent Application No. 61/125,214 filed on
Apr. 23, 2008; the entire disclosures of which are hereby fully
incorporated by reference as part of the present application.

FIELD OF THE INVENTION

[0002] The present invention relates generally to thermoplastic molding
methods and apparatus, and more particularly pertains to methods and
apparatus for injection molding thermoplastic.

BACKGROUND

[0003] Injection molding machines are expensive to purchase, require
expensive factory space and substantial quantities of electrical power.
Additionally, set-up and operation of injection molding machines is a
highly subjective trade, wherein there are significant set-up charges
each time a tool is set. Starts and stops of such machines can be very
expensive and there are always technicians and/or operators directly
involved in such activities. The general practice on start up of an
injection molding machine is provide an initial machine configuration
(e.g., screw rotation rate, operable screw barrel temperature, injection
pressure, etc.), then a "purging" process is performed where an operator
first confirms that the injection molding machine is not connected to a
mold, and then commences to process plastic but discarding the resulting
plastic melt until the operator judges that the output plastic looks hot
enough and appears to be of a low enough viscosity to commence molding
test parts. Subsequently, a plurality of test parts are produced for
inspection and/or analysis to thereby determine whether the machine is
configured appropriately to successfully produce parts having the
intended characteristics (e.g., fully conforming to the intended part
shape, density, elasticity, etc.). Accordingly, the machine settings are
generally fixed for mass producing the part.

[0004] The above described injection molding practice has substantial
problems in that various part affecting parameters can change during the
part mass production. For example, the operator settings may not be
adequate for keeping the injection machine in a state for maintaining
part consistency. In particular, it may not be possible to adequately
determine whether the plastic is sufficiently uniformly heated so that
acceptable parts can be produced therefrom. Additionally, since patches
of plastic raw material inherently vary in their composition, variation
in part production may be necessary dependent upon variation in the
plastic raw material. Furthermore, the various injection molding
parameters (whether settable by an operator or not) are generally
interrelated with respect to producing acceptable parts. For instance,
(a) nozzle injection pressure and plastic flow rate are inversely
related, (b) plastic flow rate and plastic temperature are generally
directly related, and (c) changes in screw rotation may generally be
directly related to plastic temperature, although such may depend on the
degree to which plastic heating is performed by shearing of the plastic
in the screw barrel. Accordingly, it is very difficult to effectively and
consistently configure a conventional injection molding machine to
produce acceptable quality parts, and for very small quantities of parts
the overhead for configuring such a machine can unacceptably expensive.

[0005] Accordingly, it would be advantageous to have an injection molding
system and method of operation that is substantially more cost effective
to manufacture and operate. Additionally, it is desirable for such a
system and method to be less dependent upon operator trial and error to
configure such systems for consistently producing acceptable quality
parts.

SUMMARY

[0006] A thermoplastic injection molding system and method of use is
disclosed for molding parts from heated plastics and other organic
resins, wherein the system includes an injection molding machine and a
controller for controlling the machine such that when the controller is
supplied with input from various machine sensors providing real time
measurements related to the characteristics of the plastic or resin
(collectively referred to a "plastic" hereinbelow) in the injection
molding machine, the controller dynamically adjusts the injection molding
process to achieve more consistent and reliable molded parts.

[0007] The injection molding machine disclosed herein includes a screw for
transporting the solid unmolded plastic material (e.g., pellets) from a
storage container or hopper to an injection zone or chamber for
collecting melted plastic in preparation for injecting the melted plastic
therein into mold. The screw is configured within a barrel or cylinder in
a manner that substantially prevents the plastic being conveyed therein
from being sheared, and in particular, prevents such shearing between the
barrel and the screw. Accordingly, the rotation of the screw when
conveying plastic requires substantially less torque than prior art
injection molding machines having a screw that shears the plastic. In
particular, the tolerances and configuration of the screw within the
barrel are such that the gaps between the inside diameter of the barrel
and the outside diameter of the screw are small enough so that the
plastic pellets cannot be sheared therebetween. Moreover, the barrel (and
plastic therein) is heated, insufficient heat is applied to allow the
plastic to deform into such gaps and be sheared, and insufficient heat is
applied to induce the plastic to adhere to the screw flutes or the inside
of the barrel for substantially an entire length of the screw. Thus the
present injection molding machine uses substantially less energy to
rotate the screw. Furthermore, the screw can be easily removed from the
barrel since both the screw and barrel are substantially free of adhered
to plastic.

[0008] Due to the screw being primarily a conveyance mechanism for the
plastic pellets, the screw can be designed for efficient and effective
conveyance rather than for shearing. Moreover, a result of such a screw
design in the present injection molding machine is that the pellets
compact within the barrel as they travel toward and ultimately enter
plastic melting zones of the present injection machine. Such compaction
has a particular advantage of effectively providing a barrier for
preventing melted plastic from leaking or flow backward in the injection
molding machine. Accordingly, a valve for preventing such flow back is
unnecessary. However, in the event that such compaction is diminished
enough so that there is plastic melt flow back, there may be one or more
thermocouples or other heat sensors for detecting an inappropriate
increase in heat, and providing such information to the controller (e.g.,
a computer system specifically configured for controlling the production
of parts by the present injection molding machine, and/or programmable
logic controller), wherein one or more of the following may be initiated
by the controller: an operator may be alerted, the screw rotation rate at
least temporarily increased, shutting down the mold injection machine
(e.g., in the event that there are insufficient plastic pellets in the
hopper), activating a pellet jam breaking mechanism for jams in the
hopper, and/or activating a mechanism for automatically feeding
additional pellets to the hopper.

[0009] The hereinabove described screw and a corresponding extent of the
barrel may be considered as a first zone of the injection molding
machine, wherein there is a series linearly aligned injection molding
machine zones for transforming the plastic into a melt acceptable to mold
parts. At the end of this first zone (e.g., substantially where the
plastic pellets compact), a second zone commences wherein one or more
heat sources (controlled by the controller) are active for heating the
plastic within this zone so that the plastic becomes flowable. In
general, the increase in heat over that of the first zone may be only a
few degrees above the heat applied in the first zone (e.g., an increase
in temperature in a range of 25-250° F.). The heat sources may be
one or more of a resistance, inductance or ultrasonic heat source. These
heat sources are positioned and arranged so that the heat generated
affects the plastic, within a relatively short portion of the screw, and
substantially at the termination of the screw flutes, so that the plastic
becomes flowable. More specifically, the plastic becomes sufficiently
flowable (due to pressure of additional upstream plastic moving into this
second zone) to flow downstream through heating channels of a third zone
described hereinbelow. Since most plastics do not conduct heat well, the
second zone (also known as the "transition zone" herein) may be
configured so that there is an increase in heated surface area for
contacting the plastic within this second zone. In one embodiment, such
an increase in heated surface area may be at least partially due to a
heated annular interior barrel wall that serves as an intermediary barrel
portion for connecting the barrel interior of the first zone to the
downstream third zone having a barrel interior of reduced cross sectional
dimension. In particular, the portion of the barrel extent for the first
zone may have a first diameter in a range of, e.g., 2 inches to 10
inches, and the interior dimension of the third zone may have a diameter
in a range of, e.g., 40% to 60% less. Such a heated wall provides a
substantial increase in surface area for transmitting heat to the
adjacent plastic. Moreover, such a wall can be configured to be
substantially perpendicular to the general helical path of the plastic to
thereby induce a buildup of plastic (and corresponding pressure which may
be in a range of 100-5000 psi (pounds per square inch)) adjacent to and
in contact with this wall for facilitating heat transfer to the plastic.
Additionally, the terminal end of the screw within the second zone may
terminate in a substantially convex shape (e.g., a truncated conical
surface which forces the plastic closer the heated wall). In one
embodiment, this terminal end of the screw may also radiate heat via,
e.g., one of the heat sources identified hereinabove.

[0010] It is worthwhile to note that since sufficient heat to induce
adherence of the plastic to internal machine surfaces only commences in
the second zone, and since this zone is of short length (relative to the
screw length and the length of the machine) any plastic that adheres to
the internal machine surfaces in this second zone (e.g., due to a machine
shutdown or heat interruption) will not be so substantial that the screw
cannot be readily extracted from the barrel. In particular, the linear
extent of the total barrel residing in the second zone may be only 2% to
10% of the length of the screw, and there may be few (if any) screw
portions (e.g., attenuated screw flutes) in this second zone where there
could be a sufficient buildup of resolidified plastic that would
substantially inhibit the screw from being extracted without damaging
some portion of the machine or without disassembling the barrel screw
combination from the remainder of the machine.

[0011] In the third zone following the second or transitional zone, the
flowable plastic is forced by pressure buildup in the second zone, to
flow through one or more (preferably a plurality of) channels of this
zone, wherein such channels conduct the plastic through the length of
this third zone, and into a fourth or injection zone described
hereinbelow. The channels may be distributed circumferentially about an
extension of the screw shaft, wherein in at least one embodiment this
extension includes an injection plunger that reciprocates along the
rotational axis of the screw for repeatedly injecting melted plastic into
a mold. Each channel may extend parallelly to the shaft axis between a
receiving opening for receiving plastic, and an exit opening from which
the plastic exits. The third zone is also heated by one or more of the
heat sources for continuing to elevate the temperature of the plastic
provided therein. Moreover, since the channel(s) may substantially
increase the heated barrel surface area in contact with the plastic, the
plastic in the channel(s) liquefies, or substantially reduces its
viscosity so that it may flow into the injection zone (when not
prevented) at a rate in direct proportion to the number of screw
rotations realized within the system. The temperature increase in the
plastic due the heat imparted via the channel(s) may be in a range of
25-250° F. Note that the heat sources for this third zone may be
external to the portion of the barrel for the third zone, embedded within
the barrel, and/or provided by the extension to the screw shaft (such
extension may have a length of, e.g., 1.5 inches to 12 inches depending
on the size and plastic processing capacity of the present injection mold
machine).

[0012] In at least some embodiments, the shaft extension extends (along
the axial length of the barrel) substantially the entire length of the
third zone. However, when the plunger is fully retracted into the screw
shaft, the exit opening(s) of the channel(s) opens into the injection
zone so that melted plastic can exit the channel(s) and into this
injection zone. Thus, since the melted plastic is typically under
pressure (e.g., a range of 100-1000 psi) in the channel(s), and there is
a reduced pressure in the injection zone (e.g., ambient atmospheric
pressure), plastic will flow out of the channels and into the injection
zone whenever such a pressure differential exists. However, when the
plunger extends into the injection zone for forcing plastic into a mold,
such extension closes the channel exit opening(s) so that there is
substantially no backwards flow of plastic from the injection zone into
the channel(s) due to the plunger induced pressure increase in the
injection zone. Accordingly, the plunger serves a dual purpose of both
forcing melted plastic into the mold, and also iteratively opening and
closing the channels to the injection zone. So, in particular, the
present injection mold machine requires no separate valve for metering
the plastic melt into the injection zone.

[0013] The fourth or injection zone (also identified as a "plastication
zone") includes an injection chamber for receiving plastic from the
channels, and an injection tube through which plastic flows from the
injection chamber to an injection nozzle which is attached to the mold
for providing plastic therein. As with other plastic conveying portions
of the present injection molding machine, the injection chamber and the
injection tube are connected so that the melted plastic flows generally
in a straight path along the axis of the barrel. Thus, this linear
arrangement prevents plastic pressure drops which can occur where the
pressurized liquid plastic is constrained to abruptly flow in
substantially different directions (e.g., around a 90 degree corner).

[0014] The injection zone also includes one or more of the heat sources
for providing additional heat to the plastic provided therein. As with
the heat sources in the other zones, the heat sources for the injection
zone are controlled by the controller (e.g., a computer system
specifically configured for controlling the production of parts by the
present injection molding machine, and/or programmable logic controller),

[0015] It is worthwhile to note that in one embodiment of the present
injection mold machine, a vacuum controlled break valve is provided for
control of gas (e.g., air) entering the injection zone. In particular,
the vacuum break valve allows air to enter the injection chamber when the
injection plunger lowers the pressure within the fourth zone (in
particular, the injection chamber) due to the plunger retracting from the
injection chamber and into the screw shaft extension. In at least one
embodiment, the vacuum break valve is provided along a shaft of the
plunger, wherein this plunger shaft reciprocates into and out of the
screw shaft. Accordingly, when a lower pressure (e.g., lower than ambient
atmospheric pressure) occurs in the injection chamber, the vacuum break
valve opens to introduce air into the injection chamber as will be
described further hereinbelow. During plunger retraction (toward and/or
into the screw shaft), the vacuum break valve remains open until (or just
before) the plunger retracts sufficiently so that the channels are open
to the injection chamber, and then the valve closes hereby preventing the
melted plastic entering the chamber from exiting via the valve.

[0016] It is additionally worthwhile to note that when plastic is urged
under pressure into the injection chamber, the heated gas (e.g., air)
therein readily escapes as a backflow product through, e.g., the
channel(s). Such gas backflow is facilitated in the present injection
molding machine since the screw does not tightly fit within the barrel,
and thus, gas can escape into the barrel (via the channel(s)) as plastic
enters the injection chamber. Empirical evidence indicates that when the
present injection molding machine is operating for molding acceptable
parts, the pressure in the channels is effective for rapidly filling of
the injection chamber with melted plastic. Accordingly, it is believed
that the melted plastic enters the injection chamber at sufficient
velocity to fill this chamber with melted plastic beginning with the
opposite end of the chamber from the chamber end that repeatedly provides
the plastic via the channel(s). Accordingly, since the exit opening for
providing plastic from the injection chamber to the injection tube is
located in this opposite end of the injection chamber, when the high
velocity plastic commences to fill the chamber, it does so from the
chamber opposite end. Consequently, the gas within the injection chamber
is displaced from this opposite chamber end thereby substantially
preventing gas pockets from being trapped within the plastic proximate
exit opening. Moreover, since it is believed that the melted plastic
collects within the chamber from this opposite end first, the gas within
the chamber is forced to travel backward toward the channel opening(s) as
the melted plastic under pressure injects into the injection chamber. In
some embodiments, such channel opening(s) may be shaped to facilitate the
melted plastic filling the injection chamber from the opposite end to the
chamber end having the channel opening(s). In particular, such channel
opening(s) may be shaped to direct the melted plastic into particular
portions of the injection chamber. For example, the channel opening(s)
may be shaped so that when the channel(s) initially opens, melted plastic
is directed generally toward the interior of the opposite end of the
chamber, and as the channel opening(s) widens, the melted plastic may be
generally directed to a portion of the axial centerline of the plunger
reciprocation wherein this portion is progressively closer to the channel
opening(s). Accordingly, the gas backflow may be generally along or
adjacent to the chamber sides providing relatively direct backflow paths
to the channel open(s).

[0017] Moreover, it is aspect of the present injection molding machine,
that since such escaping gas is heated to substantially the temperature
of the injection chamber, this gas may be reused to facilitate the
heating of the plastic in the second and/or the third zones.
Alternatively/additionally, such heated gas may also be recirculated back
into the injection chamber via the vacuum break valve described above.
Accordingly, the recycling/reuse of the heat within the escaping gas
increases the efficiency of the present injection molding machine.

[0018] Further note that in one embodiment, there may be backflow vents
separate from the above described channels, wherein such backflow vents
do not conduct melted plastic into the injection chamber.

[0019] The injection tube of the fourth zone may be of reduced cross
sectional area in comparison to the injection chamber, and additionally
may be of sufficient length to contain at least one volume of plastic
from the injection chamber, but generally less than two such volumes.
Accordingly, since the injection tube has an increased surface area
(relative to volume) in comparison to the injection chamber, and is also
heated, the plastic therein is acceptably liquefied for mold injection.
However, due to the relatively small volume of plastic therein, the
energy consumption of the injection molding machine is reduced over
similar prior art injection molding machines.

[0020] The fourth zone may also include a programmable nozzle valve at or
proximate to the injection nozzle, wherein this valve opens to release
melted plastic in a mold cavity when there is sufficient pressure within
the injection nozzle.

[0021] It is an aspect of the present injection molding machine that the
controller mentioned hereinabove receives various sensor readings
indicative of plastic temperatures, plastic pressures, and plastic
viscosity. In particular, the controller receives the following
measurements from the injection molding machine: [0022] (a) A pressure
measurement from a screw pressure sensor at the end of the screw opposite
the screw end terminating in the second zone. When the screw rotates to
push the plastic pellets forward, there is a corresponding back pressure
induced to push the screw in the opposite direction from the direction to
pellets move. Such back pressure is related to the quantity of pellets
being moved by the screw, and more importantly, the quantity of pellets
being compacted in the second zone. Accordingly, unless a predetermined
back pressure is sensed by the controller from the screw pressure sensor
providing such pressure measurements, the activation of the plunger will
not commence, or if already reciprocating, the plunger may cease to
reciprocate until a threshold pressure is detected by the controller from
the screw pressure sensor. [0023] (b) A temperature sensor in the first
zone for monitoring the temperature of the plastic pellets and/or the
barrel in this zone. Accordingly, the controller controls the one or more
first zone heating devices so that the pellets are heated just below
their softening or deforming temperature in the first zone. [0024] (c) A
chamber pressure sensor for sensing pressure within the injection
chamber. Unless there is at least a predetermined pressure within the
injection chamber, the injection plunger will not be activated to send a
plastic pressure wave into the injection tube and consequently cause
melted plastic to be injected into a mold cavity. Accordingly, the
present injection molding machine only forms parts when an appropriate
pressure is registered by this pressure sensor. [0025] (d) A tube
temperature sensor located in the injection tube, at or proximate to the
nozzle. Unless the plastic and/or the injection tube is determined to be
of a threshold temperature (e.g., specific to the plastic), the plunger
will not be activated, and the nozzle valve will not be opened to allow
plastic to be injected into a mold cavity. [0026] (e) A tube pressure
sensor located in the injection tube, at or near the nozzle. Unless the
plastic is determined to have a threshold pressure within the injection
tube (such pressure obtained from the most recent injection(s) of plastic
via the plunger), the nozzle valve will not be opened to allow plastic to
be injected into a mold cavity. Accordingly, the plunger may be activated
a plurality of times between openings of the nozzle valve or activated
only with nozzle valve opening depending on the pressure requirements for
the plastic within the injection tube. In some embodiments, the
controller may use the tube pressure for determining a length of time the
nozzle valve may be allowed to be open since the pressure on the melted
plastic in combination known viscosity characteristics of the plastic at
the tube temperature can be used to determine the amount of plastic that
will be injected into a mold cavity.

[0027] It is a further aspect of the present injection molding system that
it may achieve plastic and resin plastication through the conduction of
electrically generated heat as opposed to pressure induced shear heat
generation methods currently used by most injection molding machines. The
conduction of electrically generated heat provides a process of
plastication that is more accurate than shear generated heat.
Additionally, since there is also a reduced pressure applied to the
plastic (due to the lack or substantially reduced shearing), the
injection molding machine may be used to mold parts from non-traditional
materials (e.g., bio-based resins of any type, metal injection molding
feedstock, and liquid silicone) that would degrade under shearing, and
may be used to produce part with enhanced performance characteristics.

[0028] It is a further aspect of the present injection molding system and
method of use that there may be continuous material plastication that
preserves the plastic/resin quality with exact application of prescribed
levels of heat to known volumes of plastic/resin. This method
dramatically reduces the force and strength requirements for the
subsequent injection process (via the plunger), thereby allowing a more
accurate and responsive delivery of melted plastic/resin into an
injection mold cavity.

[0029] It is a further aspect of the present injection molding system and
method of use that integrated pressure and temperature sensors may be
used by the controller to accurately quantify the output of the present
injection molding machine, and in particular during the injection molding
cycle for perfecting changes to the injection molding process in order to
affect parts being produced. This is accomplished even when variations in
the raw material are present. Moreover, such real time mold injection
process changes are provided by an injection mold controller that is
data-driven from measurements obtained from sensors provided in the
injection molding machine. In particular, such a data-driven machine and
method results in various components of the present injection molding
machine having activations that are more asynchronous to one another than
the lock step or a predetermined non-deviating sequence of steps
prevalent in the prior art.

[0030] It is a further aspect of the present injection molding system and
method that this system can initiated without an operator present
(assuming the proper mold is connected to the injection molding machine,
and this machine is appropriately clean). Moreover, the presently
disclosed injection molding system and method can also operate unattended
for molding parts. Thus, activation and operation of the present
injection molding system may be performed automatically and remotely such
as via a communications network (Internet) activation, wherein the
present injection molding system and method remain unattended while
producing the desired parts.

[0031] The above described aspects of the present injection mold system
and method were combined at least in part due to the recognition of the
longstanding unmet drawbacks in various prior art injection molding
machines and methods. Moreover, even relatively recent supposedly
improvements in plastic injection mold technology have substantial
drawbacks. For example, the following recent references have been
considered, and are incorporated herein by reference: [0032] U.S.
Patent Application Publication No. 2003/0021860 by Clock et. al. filed
Jul. 24, 2001, wherein an injection molding apparatus is disclosed that
includes: an extruder configured to receive and compound raw materials, a
plunger disposed longitudinally within the extruder, and a mold
positioned at the outlet end of the extruder and configured to receive
the compounded raw materials. The extruder includes first and second
screws intermeshed with each other along at least a portion of the length
thereof. The plunger is typically positioned longitudinally within a bore
defined within the first screw and is translatable within the bore. The
method for using the apparatus includes adding at least one material to
the extruding unit proximate a first end thereof, compounding the
material, transporting the material to an outlet port proximate a second
end of the extruding unit, and transferring the material from the outlet
port to the mold via a reciprocating action of the plunger relative to
the first screw. The Clock application discloses a check ring for
preventing back flow of the liquid plastic out of an injection chamber.
Such a check ring: can be unreliable, and introduce inaccuracies into the
quantity of the plastic injected into a mold due to both the variability
in the closing by the check ring as well as the restrictions to plastic
flow therethrough. Note that such impedances to plastic flow are
magnified in that such check rings are typically heat sinks; thus,
causing the plastic to flow less readily. Moreover, it appears that the
Clock's plunger (also a heat sink having sizable plastic contacting
surface area) must rotate with the screw. Accordingly, since it is
irregularly shaped (e.g., there are flutes therein), there is unnecessary
drag on the motor rotating the screw. Additionally, since the check ring
is not monitored during operation for determining if it is performing
properly, there can be significant variability in parts produced, and for
which machine configurations settable by the operator may have an
unpredictable (if any) effect. [0033] U.S. Patent Application Publication
No. 2002/0020943 by Leopold et. al. filed May 9, 2001, wherein a molding
machine is disclosed for molding microparts containing between 0.001 to
3.5 cubic centimeters of plastic shot volume includes a plasticizing
portion operatively connected to an injection portion and a mold portion.
A valve member is provided to open and close the connection between the
plasticizing portion and the injection portion. A linear motor member is
associated with the injection portion to permit molding times of
presumably 0.01 seconds at pressures up to about 100,000 psi during
injection of the molten plastic into the mold portion. Leopold discloses
using a valve for apparently allowing melted plastic to flow into a bore
for injection into a mold. Moreover, Leopold also needs an additional
valve at his injection nozzle. There are reliability problems with such
valves since a temperature decrease of the plastic in or around such
valves can cause these valves to malfunction due to an increase in the
viscosity or solidification of the plastic. Moreover, such valves are
particularly problematic if the plastic includes one or more filler
materials that may be fibrous since such valves may fail to fully close
and/or open due to fiber build up or compaction in or around the valves.

[0034] Other features and benefits of the presently disclosed injection
molding machine and method of use are disclosed in the accompanying
figures, and the description hereinbelow. In particular, various novel
aspects of the presently disclosed injection molding machine and method
not described above may be described hereinbelow. Accordingly, this
Summary section is intended to present a general overview of the present
injection molding machine and method of use, but may not identify every
patentable aspect thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] FIG. 1 is a side view of the machine showing the logical
connections between the machine and the controller in one embodiment of
the present disclosure;

[0036] FIG. 2 is side elevation view of the machine;

[0037] FIG. 3 is a cutaway side view of the machine showing the logical
connections between the machine and the controller in one embodiment of
the present disclosure;

[0038] FIG. 3A is a detailed cutaway side view of portions of the plunger
160;

[0039] FIG. 4 is a cutaway side elevation view of the machine;

[0040] FIG. 5 is a cross-sectional view of the machine at a point
indicated as A-A in FIG. 3, viewed from left to right with reference to
FIG. 3;

[0041] FIG. 6 is a cross-sectional view of the machine at a point
indicated as B-B in FIG. 3, viewed from left to right with reference to
FIG. 3;

[0042] FIG. 7 is a cross-sectional view of the machine at a point
indicated as C-C in FIG. 3, viewed from left to right with reference to
FIG. 3;

[0043] FIG. 8 is a cross-sectional view of the machine at a point
indicated as D-D in FIG. 3, viewed from left to right with reference to
FIG. 3;

[0044]FIG. 9 is a detailed partial cutaway side elevation view of the
machine; and

[0045] FIG. 10 is a block diagram showing components of the system 12,
which includes machine 20 and controller 16 in one embodiment of the
present disclosure.

[0047]FIG. 12 is a flowchart of the processing performed by the
controller 16.

DETAILED DESCRIPTION OF THE INVENTION

[0048] In order to more fully appreciate the present invention, the
following references are fully incorporated herein: [0049] U.S. Pat.
No. 7,122,146 by Akopyan, filed Apr. 18, 2005, wherein an injection
molding machine utilizing microwave heating is disclosed. In particular,
a microwave oven and a microwave absorbent plasticizing vessel therein,
is utilized in an injection molding system to heat polymer granules to an
injection temperature and injection of a resulting plastic melt into a
cavity of an injection mold. The polymer granules may be preheated by
conventional heating systems to a temperature at which the granules
become microwave absorbent before heating to the injection temperature in
the microwave oven. The injection molding machine also contains a
hydraulic actuator for injection of the resulting plastic melt. The
ceramic materials forming the plasticizing vessel are selected to provide
equal heating rates of mold members and relatively uniform heating of
polymer to desired injection temperature. [0050] U.S. Pat. No. 7,361,294
by Pierick et. al. filed Feb. 2, 2005, wherein an injection molding
system and method is disclosed for making microcellular foamed materials
are provided as well as microcellular articles. [0051] U.S. Patent
Application Publication No. 2006/0197254 by Onishi filed May 2, 2006,
wherein an induction-heating-type heating apparatus is attached to an
area of the outer circumference of a heating cylinder adjacent to a
cooling apparatus, whereby the temperature of the heating cylinder can be
uniformly controlled to a proper value, and the temperature of the
heating cylinder can be changed quickly. An injection apparatus is
adapted to intermittently feed forward a resin within a heating cylinder
by a screw in accordance with an injection molding cycle. The injection
apparatus includes a cooling apparatus attached to a rear portion of the
heating cylinder, and an induction heating apparatus attached to the
heating cylinder to be located forward of the cooling apparatus and
adjacent to the cooling apparatus. [0052] U.S. Patent Application
Publication No. 2007/0104822 by Okabe filed Jun. 23, 2006, wherein a
plasticizing apparatus is disclosed for use with a resin material wherein
the apparatus is reduced in size and wherein a plastication state of a
resin material is presumably stabilized without raising a heating
temperature for a plasticizing barrel. On the inner surface of a
plasticizing barrel for plasticizing the resin material, one or more
lines of a heat transfer pieces shaped like a ridge is/are disposed in a
protrusion condition in a spiral or a straight line, and on the outer
surface of the barrel, one or more lines of a heat receiving piece is/are
disclosed. [0053] U.S. Patent Application Publication No. 2009/0057938 by
Zhang filed Aug. 28, 2007, wherein a method is provided for improving
melt quality in an injection unit. A closed loop control system regulates
operation of the injection unit in accordance with a reference value for
at least one operating parameter. A sensor measures the present el value
of a load upon the motor which drives an injection screw during operation
of the injection unit. A processor compares the present value of the load
to a reference value for the load. If the present value of the load
deviates from the reference value of the load by more than a
predetermined amount, then the processor may adjust the reference value
of the at least one operating parameter. Operating parameters can include
barrel temperature, back pressure and screw RPMs. [0054] U.S. Patent
Application Publication No. 2009/0045538 by Davina et. al. filed Aug. 13,
2007, wherein a method of controlling a screw in a two-stage injection
unit and a system for implementing the method is disclosed. The method is
executable at a computing apparatus associated with the two-stage
injection unit. The method comprises receiving an indication of an
operational parameter associated with the screw of the two-stage
injection unit; based on the indication of the operational parameter,
determining a target speed (STARGET) for the screw, the target speed
(STARGET) being sufficient to enable the screw to produce a required
amount of material in a molten state; causing the screw to rotate at the
target speed (STARGET), thereby causing the screw to operate in a
substantially continuous manner.

[0055] The above-identified references each have their own corresponding
drawbacks that make them at most partially useful in addressing injection
molding machine related problems.

[0056] An embodiment of the presently disclosed injection molding system
12 is shown in FIG. 1, wherein a controller 16 is shown together with the
injection molding machine 20 that the controller 16 controls. The
injection molding machine 20 will be first described hereinbelow,
followed by a description of the controller 16.

[0057] In reference to FIGS. 3 and 4, a cross sectional view of an
embodiment of the injection molding machine 20 is shown. The machine 20
includes a material hopper 24 for providing plastic material (e.g.,
plastic pellets) to the machine 20, wherein the pellets, by gravity,
enter a substantially vertical escapement 28 below the hopper 24. The
escapement 28 may be an opening in a throat block 32 which may be a metal
block (e.g., cube or other shape) acceptable for providing support and
stability to the material hopper 24 attached thereto as well as various
components of the machine 20. In particular, the throat block 32 includes
generally horizontal barrel opening 36 therethrough which intersects with
the escapement 28. The barrel opening 36 is fitted with a barrel 40 that
extends horizontally beyond the throat block 32 out one of the sides of
throat block 32. The throat block 32 also includes a plurality of water
channels 42 for circulating coolant (e.g., water or other suitable
coolant) therein since, as will become evident from the description
hereinbelow, excessive heat from the plastication of the pellets may
transfer into throat block 32 and heat the pellets in the escapement 28
or the hopper 24 excessively (e.g., wherein the pellets might be soft).
The barrel 40 provides the structural support within which the pellets
are transformed into a suitable liquid state for injection into a mold
46. The barrel 40 includes a first stage 44 extending substantially
through the throat block 32 and out of the throat block to the right in
FIG. 3. This first stage 44 is coincident in extent (along the axis 112)
with the first zone described in the Summary section hereinabove, and
accordingly such an extent may be also referred to as the first zone 44.
A cross section of the first stage 44 (in a direction traverse to the
cross section shown in FIG. 3) is shown in FIG. 5. However, a cylindrical
shape may be preferred. The first stage 44 may have a cylindrical
interior extending therethrough. The first stage 44 terminates outside
the throat block 32 at an interior annular wall 48 which reduces the
interior of the barrel 40. From this annular wall 48 and extending
further away from the throat block 32 is a second stage 52 of the barrel
40, this second stage being coincident in extent (along the axis 112)
with the second zone described in the Summary section hereinabove, and
accordingly such an extent may be also referred to as the second zone 52.
This second stage 52 may have a generally cylindrical shaped interior
which has center axis collinear with a center axis of the first stage 44.
However, instead of having a smooth cylindrical interior surface as the
first stage has, the second stage 52 includes a plurality of channels 56
in its interior side wall 58 (a representative cross section of the
second stage 52 is shown in FIG. 6), wherein these channels extend
outwardly from the center axis and such channels may be distributed about
the circumference of the second stage. Since the channels 56 extend
through the horizontal length of the second stage 52, the second stage
terminates with channel openings at each end of the second stage. The end
of the second stage distal from the first stage 44 is integral with a
third stage 60 which has therein a cylindrical injection chamber 64 that
may be of the same diameter as the second stage (excluding the channels
56), this third stage being coincident in extent (along the axis 112)
with the third zone described in the Summary section hereinabove, and
accordingly such an extent may be also referred to as the third zone 60.
The injection chamber 64 has a horizontal center axis that is collinear
with the center axes of the first and second stages 44 and 52. The
injection chamber 64 extends away from the second stage 52 until a second
diameter reducing annular interior wall 68 is reached, wherein a central
opening 72 in the wall 68 (FIG. 9) may have a center point on the center
axis of the injection chamber 64. From this second annular wall 68, a
fourth stage 76 of the barrel 40 commences which includes an injection
tube 78 that extends from an opening 72 in the second wall 68 to a nozzle
end 80 of the machine 20, wherein the nozzle end is configured for
attaching to the plastic injection mold 46 and injecting melted plastic
therein as one skilled in the art will understand. Note that this fourth
stage is coincident in extent (along the axis 112) with the fourth zone
described in the Summary section hereinabove, and accordingly such an
extent may be also referred to as the fourth zone 76. In comparison to
the diameter of the injection chamber 64, the injection tube 78 includes
a substantially reduced diameter cylindrical interior. Moreover, near or
substantially at the nozzle end 80, there is a nozzle valve 82 which
opens and closes under the direction of the controller 16. The nozzle
valve 82 remains closed until a desired plastic consistency and pressure
is detected within the injection tube 78. Once such conditions occur in
the injection tube 78, and assuming the mold 46 is in a state wherein
plastic can be accepted, the nozzle valve 82 is opened by the controller
16 for providing plastic to the mold cavity 83.

[0058] The barrel 40 also includes an opening 84 for receiving plastic
pellets from the escapement 28. Such pellets enter the barrel 40 and are
retained between the flights 88 of an auger screw 92 (also "screw"
herein) provided within the barrel. The screw 92 is preferably concentric
or coaxial with the barrel 40. The screw 92 includes a shaft 96 from
which one or more helical flights 88 project outwardly therefrom, and
such flights 88 extend from generally below the escapement 28 through the
first stage 44 of the barrel 40. The shaft 96 also extends horizontally
in the opposite direction from the escapement 28, wherein a thickened
shaft portion 100 adjacent to the throat block 32 is secured thereabout
with a bearing 104, which is provided within a mounting plate 108, which
is fixedly attached to the adjacent side of the throat block 32.
Accordingly, the bearing 104 supports and maintains alignment of the
screw 92 within the barrel 40 so that the screw can rotate about a center
axis 112 of the barrel, this center axis including the center axes for
each of the first, second, third, and fourth stages of the barrel as
described hereinabove. In particular, the screw 92 diameter within the
barrel 40 is smaller than the interior diameter of the first stage by a
tolerance of approximately 0.01 to 0.08 inches so that the screw can
rotate freely within barrel when there is no plastic in the barrel to
impede such free rotation. Note that the tolerance between the interior
of the first stage 44 and the screw 92 may be dependent upon the intended
size of the plastic pellets to be provided in the material hopper 24
since such tolerance is intended to be small enough so that such pellets
cannot be caught and sheared between the interior surface of the first
stage 44 and the portions (apexes) of the auger screw flights 88 that
rotate closest to the first stage interior surface. Accordingly, the
tolerance range above is believed appropriate for pellets that are
approximately 0.125 inches in width, height and depth, pellets being a
standard size for use in injection molding machines.

[0059] The shaft 96 also extends beyond the mounting plate 108, wherein a
pulley 116 is also secured thereabout. For rotating the screw 92, a belt
(not shown) is provided in the annular recess 120 of the pulley 116 and
also provided about a pulley of a drive motor (also not shown) for
rotating the pulley 116 and consequently the screw 92.

[0060] The screw 92 has a central bore 124 therethrough, the center axis
of the bore is coincident with the center axis 112. Within the bore 124
there is an injection plunger 160 (having a plunger head 132 and a
plunger shaft 136), and a plunger shank 140. The plunger shank 140
extends from the screw 92 rearward beyond the pulley 116. Prior to
exiting the screw 92, the plunger shank 140 and the interior surface of
the bore 124 are intermeshed via mating gear teeth 142 or another
mechanism for both supporting the shank 140 within the bore 124, and for
allowing the shank to shift along the center axis 112 under the urging of
the motor (or pneumatic cylinder, hydraulic cylinder) 144 to which the
shank end attaches via a bearing 148. In another embodiment, instead of
mating gear teeth 142, a bearing that allows the shank 140 to move in the
axial direction relative to the bore 124 and provide support for the
shank 140 within the bore 124 may replace the mating gear teeth 142.
Accordingly, the bearing 148 allows the shank 140 to rotate with the
rotation of the screw 92 by the pulley 116. However, when activated (by
the controller 16, also shown in FIGS. 1 and 3, and described
hereinbelow) the motor 144 shifts the shank along the center axis 112
either for pushing the shank further into the screw, or for extending
further rearward outside of the screw. In particular, the extent that the
shank 140 may shift in either direction does not disengage the shank from
the interior of the bore 124 at the shift mechanism 142. Moreover, length
of such a shift (in either direction) may be identical to the travel of
the plunger head 132 in the injection chamber 64 as will be further
described hereinbelow. The shank 140 attaches, at a second end thereof
opposite to the shank end attached to the motor 144, to a receptacle 152.
In one embodiment, the receptacle 152 may be threaded and the second end
of the shank 140 may have corresponding threads (e.g., male-female
junction). In particular, the receptacle 152 may threadably mate with the
end of the shank 140.

[0061] The sleeve 156 also projects beyond the fluted end of the screw 92.
The portion of the sleeve 156 that extends beyond the end of the screw 92
is within a fine tolerance of the interior surface of the second stage 52
of the barrel 40. More precisely, the smallest interior diameter of the
second stage interior side wall 58 may be within a tolerance of
approximately 0.01 inches of the outer diameter of the sleeve 156. Thus,
the sleeve 156 forms a rotatable inner most side of each channel 56 in
the second stage 52. In the present embodiment, the exterior surface of
the sleeve 156 forming the inner most channel sides may be highly
polished or otherwise provided with a coating that substantially prevents
melted or softened plastic from adhering thereto.

[0062] The sleeve 156 and the plunger head 132 are sealed together (such
combination also referred to as plunger 160), and may be considered as an
embodiment of the "shaft extension" referred in the Summary section
hereinabove. An outside diameter of the sleeve 156 may be within a fine
tolerance of the inside diameter of the injection chamber 64, e.g.,
within a range of 0.005 to 0.001, so that this sleeve 156 and plunger
head 132 combination can enter the injection chamber (via an urging by
the motor 144) for injecting melted plastic from the injection chamber
into the injection tube 78, and also via an opposite urging by the motor
144, the plunger 160 can retract out of the injection chamber 64 once the
plunger 160 reaches its full extension into the injection chamber 64.

[0063] The plunger head 132 includes a one way vacuum break valve 164
(e.g., a poppet style valve) for opening and providing a gas (e.g., air)
or other fluid substance therethrough when a reduced atmospheric pressure
occurs in the injection chamber 64 relative to a pressure on an opposite
side of this valve, and remaining closed otherwise. When the valve 164
opens, the gas provided to the injection chamber 64 comes, in one
embodiment, from within the bore 124, and more particularly, from within
a plunger vent 168 within the plunger shaft 136 (FIG. 3A). However, it is
within the scope of the present disclosure that such gas may come from a
backflow of gas (i.e., in an opposite direction from the flow of plastic
toward the nozzle end 80) through the channels 56. The vacuum break valve
164 may be configured for opening when there is a pressure differential
between sides of the valve in a range of 2 to 1,000 psi. Accordingly,
when the plunger 160 retracts back into the screw 92, the vacuum break
valve 164 opens so that the retraction of the plunger does not cause the
melted plastic within the injection tube 78 to withdraw back into the
injection chamber 64.

[0064] The injection molding machine 20 also includes a plurality of heat
sources (e.g., such heat sources may generate heat via electrical
resistance, electrical inductance, microwave or ultrasonic energy)
distributed about and in contact with (or proximate to) various portions
of the barrel 40. In particular, one or more such heat sources 172 may
surround the barrel 40 in a later or terminal portion of the barrel first
stage 44 near the commencement of the barrel second stage 52, and
continue to surround barrel 44 in substantially the second stage 52. The
heat sources 172 (under the control of the controller 16) preheat the
plastic pellets to a point just below the softening point of the plastic.

[0065] The heat sources 172 (under the control of the controller 16) heat
the plastic pellets therein to a temperature where they become at least
soft and deformable for flowing into the channels 56 due to the pressure
exerted on such deformable pellets from additional pellets moving into
the second stage 52.

[0066] The steps performed by the controller 16 for appropriately
activating and deactivating the heat sources 172 are described
hereinbelow in the section entitled "Controller Operation". Note that in
one embodiment, an additional heat source 176 (not shown in figures) may
be placed on a different location of the barrel 44 and controlled by
controller 16. Note that in such an embodiment of the controller 16 the
heat sources 172 and 176 are activated and deactivated in unison by the
same processing in the controller 16. That is, the controller may not
distinguish between the heat sources 172 and 176. In another embodiment,
heat sources 172 and 176 may be activated, for example, in a serial or
sequential manner.

[0067] An additional one or more heat sources 180 may surround the barrel
40 in substantially its third stage 60 and fourth stage 76. The heat
sources 180 (under the control of the controller 16) further heat the
plastic in the injection chamber 64 and the injection tube 78 so that the
temperature of the plastic is above a minimum threshold to be injected
into the mold cavity 83. The steps performed by the controller 16 for
appropriately activating and deactivating the heat sources 180 are also
described hereinbelow in the section entitled "Controller Operation".

[0068] The injection molding machine 20 also includes a plurality of
sensors for communicating measurements related to plastic processing to
the controller 16. In one embodiment of the injection molding machine 20,
there is a screw 92 pressure sensor (denoted "PT1" herein) attached,
e.g., to the screw end between the pulley 116 and the motor 144, wherein
this sensor measures the forces on the screw, wherein such forces are
substantially along the center axis 112, and induced by the compaction of
the plastic in first and second barrel stages 44 and 52. Accordingly,
such for forces are in the direction for pushing the screw 92 out of the
end of the barrel 40 provided in the throat block 32.

[0069] The injection molding machine 20 also includes a plurality of
sensors for communicating measurements related to plastic processing to
the controller 16. In one embodiment of the injection molding machine 20,
there is a screw 92 pressure sensor or pressure transducer (denoted "PT1"
herein) attached, e.g., to the screw 92 end between the pulley 116 and
the motor 144, wherein this sensor measures the pressure on the screw,
wherein such pressure is substantially along the center axis 112, and
induced by the compaction of the plastic in first and second barrel
stages 44 and 52. Accordingly, such for pressure may be considered a
force in a direction for pushing the screw 92 out of the end of the
barrel 40 provided in the throat block 32. A temperature sensor (denoted
"TC1" herein) is attached to the barrel 40 (more particularly, the third
stage thereof) for detecting temperatures in the injection chamber 64.
The sensor TC1 may be a thermocouple as one skilled in the art will
understand. Also attached to the barrel third stage is a pressure sensor
or pressure transducer (denoted "PT2" herein) for measuring the pressure
within the injection chamber 64. Downstream from the sensor PT2 is
another pressure sensor or pressure transducer (denoted "PT3" herein),
wherein this sensor measures the pressure within the injection tube 78.
Additionally, there is a temperature sensor (denoted "TC2" herein) is
attached to the barrel 40 (more particularly, the fourth stage thereof)
for detecting temperatures in the injection chamber 64. The sensor TC2
may be a thermocouple as one skilled in the art will understand. Finally,
there is a temperature sensor (e.g., a thermocouple) provided in the mold
46 for detecting temperatures therein. This last sensor identified as
"TC3". Each of the above identified sensors provides their corresponding
readings to the controller 16 as will be described in further detail
hereinbelow.

[0070]FIG. 11 shows a block diagram of the injection molding system 12,
wherein additional detail is provided of the internal components of the
controller 16. Referring to the controller 16, it includes a main
controller 204 that performs that high level control functionality for
controlling the injection molding machine 20. A flowchart of the
processing performed by the main controller 204 is presented in FIG. 12
described hereinbelow. The main controller 204 activates a plurality of
subcontrollers that may perform their tasks asynchronously from one
another. In particular, subcontroller 304 is provided for controlling the
heat source(s) 172 for heating the first and second zones 44 and 52. A
subcontroller 308 is provided for controlling the heat source(s) 180 for
heating the third and fourth zones 60 and 76. A subcontroller 312 is
provided for controlling the screw 92 rotation during startup of the
injection molding machine 20, and more particularly, prior to injection
molding machine entering a plastic processing state where processed
plastic is flowing through the injection molding machine appropriately
for making parts. A subcontroller 316 is provided for controlling the
screw 92 rotation once plastic is flowing through the injection molding
machine appropriately for making parts. A description of each of these
subcontrollers is provided hereinbelow. However, prior to providing such
descriptions, a description of the flowchart of FIG. 12 representing the
processing performed by the main controller 204 is provided.

[0071] Referring to FIG. 12, in step 404, the controller 16 receives input
for activating the injection molding system 12. Such activation may be
from an operator at the injection molding system 12, or an operator that
is remote from the location of the system 12. Moreover, since the
controller 16 can be remote from the injection molding machine 20 (e.g.,
in communication therewith via a communications network such as the
Internet), the operator may reside at the controller site, or at the
injection molding machine site. Alternatively/additionally, the operator
may not reside at the site for either the controller 16 or the injection
molding machine 20, but instead may communicate with controller via a
communications network. Moreover, the input received may be from another
computational system such as an inventory management system that
automatically requests additional parts to be produced by the injection
molding system 12.

[0072] Note that such input may include a type of material to be supplied
to the injection molding machine 20, an identification(s) of the part(s)
to be molded, the quantity of parts to be produced.

[0073] In step 408 of FIG. 12, the controller identifies from the input
received the type of material to supply to the injection molding machine
20. Such identification may be precisely identified in the input, or may
be only generally identified (e.g., by a plastics chemical family, or by
required part functionality such as elasticity, compression strength,
biodegradable, acceptable for retention in a human body, non-toxic if
ingested, etc. In one embodiment, such material may be automatically
supplied to the hopper 24 for commencing to produce the parts desired,
and the desired mold 46 may be automatically attached to the injection
molding machine 20, e.g., once the mold is located in an inventory of
molds 46. Subsequently, in step 412, a database management system 410
(FIG. 11) may be accessed for determining the injection molding machine
20 parameters to use in molding the desired parts.

[0074] In step 416, the subcontroller 304 is activated for controlling the
heat source(s) 172 for heating the second and third zones 44 and 52. The
input to the subcontroller 304 may include a desired start temperature
range for readings from the temperature sensor TC1 as determined for
plastic to be processed; the range of temperatures may be, e.g., +/-10
degrees F., and the range may be a set point range identified as the
range [set_pt_low, set_pt_hi] wherein set_pt_low is a low set point for
the readings from TC1, and set_pt_hi is a high set point for these
readings. Psuedo-code representative of the processing performed by the
subcontroller 304 is as follows:

TABLE-US-00001
Subcontroller 304 processing:
Activate asynchronously (the following processes):
Process 1:
At "X" frequency read input temperature measurement from TC1;
If the input temperature measurements are below "set_pt_low", then
Make sure the heat sources 172 are activated for heating;
Else make sure the heat sources 172 are not heating;
Process 2:
Repeat every "Y" time interval:
If (Delta12_Not_Measured) then /* "Delta12_Not_Measured"
is set to TRUE
after the plunger 160 retracts into
the screw 92
*/
If (the plunger 160 is fully retracted into the screw 92)
then {
Pt1 Read PT1;
Pt2  Read PT2;
Delta12  Pt1 - Pt2;
Delta12_Not_Measured  FALSE;
If (Delta12 >= its corresponding predetermined set point)
then {
/* either plastic viscosity in screw 92 is high, and/or,
plastic is
not flowing through channels 56 into the injection
chamber 64
*/
Tcl  read TC1;
If (Tc1 <= set_pt_hi) then
Override Process 1, and make sure the heat sources 172 are
heating;
}
Until (subcontroller 304 is deactivated).

[0075] Referring to the subcontroller 304 psuedo-code hereinabove, process
1 and process 2 may be activated for being performed simultaneously.
However, note that process 2 can override process 1 to force the heat
source(s) 172 to heat zones 44 and 52. It is believed that an important
aspect of the controller 16 is the use of the pressure measurements from
the sensors PT1 and PT2 to modulate the heat delivered to the first and
second zones 44 and 52. In particular, the computation of "Delta12"
provides a quantitative index as to whether plastic viscosity in screw 92
is high, and/or the plastic is not flowing through channels 56 into the
injection chamber 64. For example, if the value Pt1 is high relative to
the value of Pt2, then there is substantial pressure in the first and
second zone 44 and 52 for pushing the screw 92 out the rear end of the
injection molding machine 20, and little (if any) plastic in the
injection chamber 64. Accordingly, this is indicative of the plastic in
the second and third zones 52 and 60 not being hot enough to proper flow
through the channel 56 and into the injection chamber 64. Thus, in this
case, any deactivation of the heat source(s) 172 is overridden by process
2. Note that it may be important for the reading of PT1 and PT2 to be
taken substantially simultaneously, and that the readings of PT2 be taken
when the pressure in the injection chamber 68 is not being impacted by
the movement of the plunger 160 into or out of the injection chamber.
Accordingly, such reading are only taken when the controller 16 detects
that the plunger is fully retracted from the injection chamber 64. The
use of the Boolean variable "Delta12_Not_Measured" assists in making sure
the readings are taken at a proper time.

[0076] In step 420, the subcontroller 308 is activated for controlling the
heat source(s) 180 for heating the fourth zone 76. As described in the
pseudo-code following. Note that the input for this subcontroller is: a
desired start temperature range for readings from the temperature sensor
TC2 (for heat sources 180) for plastic to be processed, the range of
temperatures (e.g., +/-10 degrees F.) creating a set point range, i.e., a
range: [set_pt_low2, set_pt_hi2] for the readings from TC2.

TABLE-US-00002
Subcontroller 308 processing:
Activate asynchronously (the following processes):
Process 3:
At "X" frequency the subcontroller 308 reads input temperature
measurements from TC2;
If the input temperature measurements are below "set_pt_low2", then
Make sure the heat sources 180 are activated for heating;
Else make sure the heat sources 180 are not heating.
Process 4:
Repeat every "Y" time interval:
If (Delta23_Not_Measured) then /* "Delta23_Not_Measured"
is set to TRUE
after the plunger 160 retracts into
the screw 92
*/
If (the plunger 160 is fully retracted into the screw 92)
then {
Pt2 Read PT2;
Pt3  Read PT3;
Delta23  Pt2 - Pt3;
Delta23_Not_Measured  FALSE;
If (Delta23 >= its corresponding predetermined set point)
then {
/* either plastic viscosity in injection chamber 64 is high,
and/or, plastic is not flowing through injection tube 78 */
Tc2  read TC2;
If (Tc2 <= set_pt_hi2) then
Override Process 3, and make sure the heat sources
180 are heating;
}
Until (subcontroller 308 is deactivated).
Note that the variables "Delta23" and "Delta23_Not_Measured" have similar
meanings as "Delta12" and "Delta12_Not_Measured" described hereinabove.

[0077] Subsequently, step 424 is performed, wherein the subcontroller 312
is activated for controlling the screw 92 rotation. Pseudo-code
describing the actions performed by this subcontroller follow.

TABLE-US-00003
Subcontroller 312 processing:
Repeat at predetermined intervals:
If (the input temperature measurements are in the range
[set_pt_low, set_pt_hi])
then
Make screw 92 is rotating Until (PT1 indicates back pressure exceeds
maximum pressure allowed) OR (PT2 indicates pressure from
plastic presence is above a predetermined set point);
If (PT1 indicates back pressure exceeds maximum pressure) then
Stop the screw 92 for an elapsed time "X", and PT1 pressure
readings are monitored at "X" time intervals. When PT1 drops
below maximum pressure allowed, the screw 92 is rotated;
If (PT2 indicates pressure from plastic presence is above a
predetermined minimum set point) then
The screw 92 is stopped until pressure at PT2 falls below the
predetetmined minimum set point for PT2, and PT2 pressure
readings are monitored pressure at "X" time intervals. When PT2
drops below the predetermined minimum set point for PT2, the
screw 92 is rotated;
Until (subcontroller 312 is deactivated).

[0078] Subsequently, in step 428, the expression: (the most recent value
of pt2 by subcontroller 304 is within its corresponding predetermined set
point range) AND (the most recent value of Delta12 computed by
subcontroller 304 is within a predetermined set point range) is
repeatedly evaluated. When this expression evaluates to "TRUE", the
subcontroller 312 is deactivated and the subcontroller 316, whose
pseudo-code is hereinbelow, is activated.

TABLE-US-00004
Subcontroller 316 processing:
Repeat at predetermined intervals:
If ((the most recent value of Pt3 indicates a pressure below its minimum
corresponding predetermined low set point) OR (the most recently
computed value for Delta23 is outside of its predetermined set point
range) then
Make sure screw 92 is rotating;
If (the most recent value of Pt3 indicates pressure exceeds maximum
set point pressure) then
Stop the screw 92 for an elapsed time "X", and PT1 pressure readings
are monitored at "X" time intervals. When PT1 drops below
maximum pressure allowed, commence rotating the screw 92;
If (the most recent value of Pt2 indicates pressure is above a
predetermined minimum set point) then
The screw 92 is stopped ", and PT2 pressure readings are monitored
at "X" time intervals. When PT2 drops below the predetenained
minimum set point for PT2, commence rotating the screw 92;
Until (subcontroller 316 is deactivated).

[0079] Subsequently, step 440 is performed.

[0080] When an appropriate profile is achieved by measurements of the heat
source(s) 172 and heat source(s) 180 sequences via their corresponding
sensors, we then have a volume of material where the viscosity as
measured as resistance to flow, is optimized and known. When this
condition is achieved we will have realized a low delta between PT1 and
PT2 and furthermore a low delta between PT1 and PT3. This allows the use
of the screw 92 to extrude plastic directly into the mold 46 when
desired.

[0081] In any of the following modes of injection molding, operation of
the last key component is PT4 pressure transducer in the injection mold.

[0082] The above disclosure lays the foundation for four different
injection molding processes: Plastic Injection Molding Method (PIMM) 1
through 4 described hereinbelow. [0083] (a) PIMM1--the Injection
Plunger is advanced beyond the truncation of the Lobe Geometry to
evacuate the Injection Zone. As the Injection Plunger advances the Nozzle
valve is opened to allow flow of plastic into the injection mold causing
the mold cavity to fill and plunger travel ceases upon satisfying
predetermined pressure set point as indicated by PT4. [0084] (b)
PIMM2--Screw Auger rotates continuously to extrude plastic and the Nozzle
valve is opened to allow flow of plastic into the injection mold causing
the mold cavity to fill to some predetermined percentage through plastic
extrusion (low speed, low shear) when the Injection Plunger is then
utilized to finish the injection process to the predetermined pressure
set point as indicated by PT4 at which time plunger travel ceases. [0085]
(c) PIMM3--Screw Auger rotates continuously to extrude plastic and the
Nozzle valve is opened to allow flow of plastic into the injection mold
causing the mold cavity to fill completely by extrusion (low speed, low
shear) to the predetermined pressure set point as indicated by PT4 at
which time extrusion ceases. [0086] (d) PIMM4--Screw Auger rotates
continuously to extrude plastic and the Nozzle valve is opened to allow
flow of plastic into the injection mold causing the mold cavity to begin
filling when the Injection Plunger is then utilized to cycle repeatedly
until realizing predetermined pressure set point as indicated by PT4 at
which time plunger travel ceases.

[0087] The foregoing discussion of the injection molding system 12 has
been presented for purposes of illustration and description. Further, the
description is not intended to limit the invention(s) disclosed herein
any to the form disclosed. Consequently, variation and modification
commiserate with the above teachings, within the skill and knowledge of
the relevant art, are within the scope of the present invention. The
embodiment described hereinabove is further intended to explain the best
mode presently known of practicing the invention, and to enable others
skilled in the art to utilize each invention herein, or in other
embodiments thereof, and as may be provided with the various
modifications required by their particular application or uses of the
invention(s) herein.